Principal Materials and Process Engineer – Banbury, United Kingdom
£95K DOE + Performance Bonus
About the Role
Morson are proud to partner with a leading aerospace company based in Banbury, who are at the forefront of developing next-generation composite technologies.
We're looking for a Principal Materials and Process Engineer to take on a pivotal leadership role within a highly skilled engineering team.
In this role, you will act as the lead Material Process specialist, driving the introduction of a novel composite material system produced using a high-rate manufacturing process that's brand new to the aerospace sector.
This is an exceptional opportunity for an experienced engineer to work in a fast-paced, innovative environment where new materials and processes are being shaped for future aerospace platforms.
Key Responsibilities
* Lead the development and introduction of new composite material systems and processing technologies.
* Author detailed materials and process specifications for resin, fibre, composite processes, inspection, and assembly.
* Define and manage test plans for physical, chemical, and mechanical property characterisation.
* Develop new test methods to address gaps in existing ASTM and industry standards.
* Perform statistical analysis of test data and produce high-quality technical reports for customer and certification use.
* Ensure compliance with global chemical legislation (e.g., REACh).
* Keep company strategy aligned with emerging MsP technologies and best practices.
* Provide technical guidance and problem‑solving support for all MCP‑related issues.
* Collaborate with metallic materials specialists to define metals and associated processes, including heat treatment and corrosion protection.
About You
* Deep understanding of Polymer Matrix Composites (PMCs) – including matrix types, fibres, manufacturing technologies, and in‑service performance.
* Proven experience authoring MsP specifications for composite systems.
* Experience working with OEMs and/or regulators to certify PMC materials and structures for aerospace applications.
* Knowledge of dry fibre processing and resin infusion technologies.
* Experience developing test methods for PMC material characterisation.
* Familiarity with thermal analysis techniques (DSC, DMA).
* Degree in Materials Science, Polymer Science, Mechanical Engineering, or a related field.
* Highly motivated, proactive, and able to work on your own initiative.
* Strong communication skills with a collaborative approach.
* Analytical mindset with a sound grounding in solid mechanics and first‑principle analysis.
* Interest in contributing to industry working groups (e.g., ASTM D30, CMH‑17).
What's on Offer
* Salary up to £95K, depending on experience.
* Performance‑based bonus scheme.
* Pension scheme – up to 10% employer contribution.
* Private medical insurance – comprehensive health cash plan.
* 25 days annual leave + bank holidays.
* Flexible benefits package, including:
1. Holiday buy/sell options.
2. Discounted gym memberships.
3. Enhanced maternity, adoption, and paternity leave.
4. Structured training and clear career progression pathways.
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